Polyolefin Composition Comprising Polypropylene Polymers and Recycled Plastic Materials

Abstract

Provided is polyolefin composition including a) 35-65 wt % (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer with a total ethylene C2 content of 6-15 wt %, an ethylene content of the soluble fraction C2 (SF) content of 25-40 wt % and with a melt flow rate MFR 2 (230° C., 2.16 kg, measured according to ISO 1133) in the range of 60 to 90 g/10 min; and b) 35-65 wt % (based on the overall weight of the polyolefin composition) of a blend of recycled plastic material comprising polypropylene and polyethylene in a ratio of 3:7 to 49.5:1, which is recovered from a waste plastic material derived from post-consumer and/or post-industrial waste, c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt %.

1 . A polyolefin composition comprising
 a) 35-65 wt % (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer with a total ethylene C2 content of 6-15 wt %, an ethylene content of the soluble fraction C2 (SF) content of 25-40 wt % and with a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133) in the range of 60 to 90 g/10 min; and   b) 35-65 wt % (based on the overall weight of the polyolefin composition) of a blend of recycled plastic material comprising polypropylene and polyethylene in a ratio of 3:7 to 49.5:1, which is recovered from a waste plastic material derived from post-consumer and/or post-industrial waste,   c) optionally further additives, wherein the sum of all ingredients always adds up to 100 wt %,   characterized by
 an impact strength (ISO179-1, Charpy 1 eA+23° C.) of 5-8 kJ/m 2 , 
 a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133) of 30 to 80 g/10 min, and 
 a tensile modulus (Iso 527-2) of 1450 to 1600 MPa. 
   
     
     
         2 . The polyolefin composition according to  claim 1 , comprising:
 a) 40-60 wt % (based on the overall weight of the polyolefin composition) of the at least one heterophasic polypropylene copolymer;   b) 40-60 wt % (based on the overall weight of the polyolefin composition) of the blend of recycled plastic material comprising polypropylene and polyethylene,   and optionally further additives, wherein the sum of all ingredients always adds up to 100 wt %.   
     
     
         3 . The polyolefin composition according to  claim 1 , having an impact strength (ISO179, Charpy 1 eA+23° C.) of 5.2 to 7.5 kJ/m 2 . 
     
     
         4 . The polyolefin composition according to  claim 1 , having a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133-1) of 30 to 75 g/10 min. 
     
     
         5 . The polyolefin composition according to  claim 1 , having a tensile modulus (ISO 527-2) of 1450 to 1550 MPa. 
     
     
         6 . The polyolefin composition according to  claim 1 , wherein the at least one heterophasic polypropylene copolymer a) is selected from a group comprising
 at least one heterophasic polypropylene copolymer (PPHeco-1) having a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133) of 60 to 90 g/10 min;   at least one heterophasic polypropylene copolymer (PPHeco-2) having a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133) of 60 to 90 g/10 min.   
     
     
         7 . The polyolefin composition according to  claim 1 , wherein the blend of recycled plastic material comprising polypropylene and polyethylene has a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133) of at least 5 g/10 min. 
     
     
         8 . The polyolefin composition according to  claim 1 , wherein the blend of recycled plastic material comprises a relative amount of units derived from propylene of greater than 50 wt % with respect to the total weight of the blend of recycled plastic material. 
     
     
         9 . The polyolefin composition according to  claim 1 , wherein the blend of recycled plastic material comprises a relative amount of units derived from ethylene of less than 47 wt % with respect to the total weight of the blend of recycled plastic material. 
     
     
         10 . The polyolefin composition according to  claim 1 , wherein the polyolefin composition is obtained by extruding the at least one heterophasic polypropylene copolymer and the blend of recycled plastic material in the presence of at least one peroxide. 
     
     
         11 . A process for preparing the polyolefin composition according to  claim 1 , comprising
 providing
 a) 35-65 wt % (based on the overall weight of the polyolefin composition) of at least one heterophasic polypropylene copolymer with a melt flow rate MFR 2  (230° C., 2.16 kg, measured according to ISO 1133) of 60 to 90 g/10 min; and 
 b) 35-65 wt % (based on the overall weight of the polyolefin composition) of a blend of recycled plastic material comprising polypropylene and polyethylene in a ratio 3:7 to 49.5:1, which is recovered from a waste plastic material derived from post-consumer and/or post-industrial waste, 
 feeding/dosing the at least one heterophasic polypropylene copolymer and the blend of recycled plastic material separately or as a mixture into at least one extruder, 
 melting the mixture in the at least one extruder, 
 adding at least one peroxide to the molten mixture in the at least one extruder, and 
 optionally pelletizing the obtained polyolefin composition. 
   
     
     
         12 . The process according to  claim 11 , wherein the blend of recycled plastic material is fed into at least one first extruder, is molten in the first extruder and the melt is subsequently fed into at least one second extruder, wherein at least one heterophasic polypropylene copolymer is dosed into the at least one second extruder and the at least one peroxide is added to the molten mixture of the recycled plastic material and the heterophasic copolymer in the second extruder. 
     
     
         13 . The process according to  claim 11 , wherein flakes of recycled plastic material are dosed into a combination of a single and double screw extruder, wherein in the single screw extruder the recycled plastic material flakes are purified, molten, and optionally provided with additives, the melt of recycled plastic material is subsequently fed into the second double screw extruder, wherein the at least one heterophasic polypropylene copolymer and the at least one peroxide are added to the melt of recycled plastic material. 
     
     
         14 . (canceled) 
     
     
         15 . An article comprising the polyolefin composition according  claim 1 . 
     
     
         16 . The polyolefin composition according to  claim 1 , wherein the additive(s) comprise at least one of sterically hindered phenol(s), phosphorous based antioxidant(s), sulphur based antioxidant(s), nitrogen-based antioxidant(s), and/or mixtures thereof. 
     
     
         17 . The polyolefin composition according to  claim 1 , wherein the additive(s) comprise at least one dosing agent which comprises a polypropylene homopolymer with melt flow rates MFR 2  of 1 to 5 g/10 min and a density of 800 to 100 kg/m 3 . 
     
     
         18 . The polyolefin composition according to  claim 1 , wherein the at least one heterophasic polypropylene copolymer and the blend of recycled plastic material are provided in granular form and/or as flakes. 
     
     
         19 . The polyolefin composition according to  claim 11 , wherein the at least one peroxide comprises 2,5-Dimethyl-2,5-di(tert-butylperoxy)hexane. 
     
     
         20 . The polyolefin composition according to  claim 11 , wherein the at least one peroxide is added to the molten mixture in the at least one extruder in an amount of at least 0.5 wt % based on the overall weight of the polyolefin composition.